Alkoxylation process using calcium based catalysts

Claim 2

A process for preparing an alkoxylation catalyst comprising: forming a catalyst pre-mix by admixing an alkoxylated alcohol mixture containing an alkoxylated alcohol having the general formula R₁ - O CH₂CH₂ - O n H where R₁ is a hydrocarbon radical containing from about 1 to about 30 carbon atoms and n is from about 1 to about 20 and from about 1 to about 60% by weight free alcohol, a calcium containing compound which is at least partially dispersible in said alkoxylated alcohol mixture, an inorganic acid, and an aluminum alkoxide having the general formula where R₂, R₃ and R₄ is each a hydrocarbon radical containing from about 1 to about 30 carbon atoms, said calcium containing compound and said alkoxylated alcohol mixture being mixed prior to addition of said aluminum alkoxide; and heating said catalyst pre-mix to a temperature and for a time sufficient to effect at least a partial exchange reaction between the alkoxide groups of said aluminum alkoxide and said hydroxyl group of said alkoxylated alcohol and thereby form an active alkoxylation catalyst.

Claim 3

The process of Claim 1 wherein R₁ is a hydrocarbon radical containing from about 8 to about 14 carbon atoms.

Claim 4

The process of Claim 1 wherein n is from about 1 to about 12.

Claim 5

The process of Claim 1 wherein n is from about 1 to about 4.

Claim 6

The process of Claim 1 wherein R₂, R₃ and R₄ is each a hydrocarbon radical containing from about 8 to about 14 carbon atoms.

Claim 7

The process of Claim 1 wherein said calcium containing compound is selected from the group consisting of calcium oxide, calcium hydroxide and mixtures thereof.

Claim 8

The process of Claim 1 wherein said inorganic acid is selected from the group consisting of sulphuric acid and hydrochloric acid.

Claim 9

The process of Claim 1 wherein the mole ratio of said calcium containing compound to said aluminum alkoxide is from about 1:1 to about 10:1, calculated as calcium and aluminum, respectively.

Claim 10

The process of Claim 1 wherein the mole ratio of said inorganic acid to said aluminum alkoxide is from about 0.25:1 to about 4:1, calculated as acidic hydrogen and aluminum, respectively.

Claim 11

The process of Claim 1 including adding to said pre-mix an organic acid which is more readily miscible in hydrocarbon solvents than in water.

Claim 12

The process of Claim 1 including removing water from said pre-mix prior to the addition of said aluminum alkoxide.

Claim 13

A process for the alkoxylation of an alcohol comprising: forming a catalyst pre-mix by admixing an alkoxylated alcohol having the general formula R₁ - O CH₂CH₂ - O n H where R₁ is a hydrocarbon radical containing from about 1 to about 30 carbon atoms and n is from about 1 to about 20, a calcium containing compound which is at least partially dispersible in said alkoxylated alcohol, an inorganic acid, and an aluminum alkoxide having the general formula where R₂, R₃ and R₄ is each a hydrocarbon radical containing from about 1 to about 30 carbon atoms, said calcium containing compound and said alkoxylated alcohol being mixed prior to addition of said aluminum alkoxide; heating said catalyst pre-mix to a temperature and for a time sufficient to effect at least a partial exchange reaction between the alkoxide groups of said aluminum alkoxide and said hydroxyl group of said alkoxylated alcohol and thereby form an active alkoxylation catalyst; and introducing an alcohol reactant and an alkylene oxide under alkoxylation conditions to thereby produce alkoxylated derivates of said alcohol reactant.

Claim 14

A process for the alkoxylation of an alcohol comprising: forming a catalyst pre-mix by admixing an alkoxylated alcohol having the general formula R₁ - O CH₂CH₂ - O n H where R₁ is a hydrocarbon radical containing from about 1 to about 30 carbon atoms and n is from about 1 to about 20, a calcium containing compound which is at least partially dispersible in said alkoxylated alcohol, an inorganic acid, and an aluminum alkoxide having the general formula where R₂, R₃ and R₄ is each a hydrocarbon radical containing from about 1 to about 30 carbon atoms, said calcium containing compound and said alkoxylated alcohol being mixed prior to addition of said aluminum alkoxide; heating said catalyst pre-mix to a temperature and for a time sufficient to effect at least a partial exchange reaction between the alkoxide groups of said aluminum alkoxide and said hydroxyl group of said alkoxylated alcohol and thereby form an active alkoxylation catalyst; and introducing an alcohol reactant and an alkylene oxide under alkoxylation conditions to thereby produce alkoxylated derivates of said alcohol reactant.

Claim 15

The process of Claim 12 wherein R₁ is a hydrocarbon radical containing from about 8 to about 14 carbon atoms.

Claim 16

The process of Claim 12 wherein n is from about 1 to about 12.

Claim 17

The process of Claim 12 wherein n is from about 1 to about 4.

Claim 18

The process of Claim 12 wherein R₂, R₃ and R₄ is each a hydrocarbon radical containing from about 8 to about 14 carbon atoms.

Claim 19

The process of Claim 12 wherein said calcium containing compound is selected from the group consisting of calcium oxide, calcium hydroxide and mixtures thereof.

Claim 20

The process of Claim 12 wherein said inorganic acid is selected from the group consisting of sulphuric acid and hydrochloric acid.

Claim 21

The process of Claim 12 wherein the mole ratio of said calcium containing compound to said aluminum alkoxide is from about 1:1 to about 10:1, calculated as calcium and aluminum, respectively.

Claim 22

The process of Claim 12 wherein the mole ratio of said inorganic acid to said aluminum alkoxide is from about 0.25:1 to about 4:1, calculated as acidic hydrogen and aluminum, respectively.

Claim 23

The process of Claim 12 including adding to said pre-mix an organic acid which is more readily miscible in hydrocarbon solvents than in water.

Claim 24

The process of Claim 12 including removing water from said pre-mix prior to the addition of said aluminum alkoxide.

Claim 25

The process of Claim 12 wherein said alkylene oxide comprises ethylene oxide.

Claim 26

The process of Claim 12 wherein said alcohol is a monohydric aliphatic alcohol containing from 8 to 14 carbon atoms.